0438544 JOHNSON IMPELLER HOUSING

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     2P-5518     Bearing Tool     1    
B     -     Plastigage     -    
C     8T-5096     Dial Indicator Group     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00503404
Typical exampleNote: Ensure that the main bearings are installed so that bearing tabs (3) fit into the notch in the cylinder block and in the main bearing caps.Note: Install the main bearings without lubricant when the check for the crankshaft main bearing clearance is made. Put clean engine oil on the crankshaft main bearings for final assembly.
Install new crankshaft main bearings in the main bearing caps.
Illustration 2 g00503174
Typical example
Install the upper halves of the main bearings in the cylinder block with Tooling (A) .
Illustration 3 g00566702
Typical exampleThe engine is inverted on 4C-9832 Engine Roll-Over Stand .Note: When the bearing clearance is checked and the engine is in an upright position or on a side position, the crankshaft must be supported against the upper halves of the main bearings. This is done in order to get a correct measurement with Tooling (B) . If the crankshaft is not supported, the weight of the crankshaft will cause an incorrect reading. If the engine is inverted it is not necessary to hold the crankshaft upward. Do not rotate the crankshaft when Tooling (B) is installed.Note: Refer to Guideline For Reusable Parts, SEBV0544, "Engine Bearings and Crankshafts" for complete details concerning measuring of bearing clearances.
Use Tooling (B) to check the crankshaft main bearing clearances. Follow Step 5 and Step 6 for the correct installation procedures and tightening procedures for the main bearing caps when the clearance check is performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check".Bearing clearance (new bearings) ... 0.091 to 0.186 mm (0.0036 to 0.0073 inch)Maximum permissible bearing clearance (used bearings) ... 0.25 mm (0.010 inch)
Illustration 4 g00503665
Typical example
Illustration 5 g00503673
Typical exampleNote: Ensure that the numbers on the main bearing caps match the numbers on the cylinder block. The arrows (4) on the main bearing caps are toward the front of the cylinder block.Note: Install the thrust plates with the identification "Block Side" toward the cylinder block.
Lubricate the threads of the main bearing cap bolts with clean engine oil.
Install the main bearing caps in the appropriate order. Follow the tightening procedure in Step 6. 3412EInstall the main bearing caps for No. 2 through No. 6 main bearings. Be sure to install the thrust plates on the No. 4 main bearing cap.Remove No. 1 and No. 7 main bearing caps after No. 2 through No. 6 main bearing caps have been installed. Refer to Disassembly and Assembly, "Crankshaft Main Bearings - Remove".Install the No. 1 and No. 7 main bearing caps. 3408EInstall the main bearing caps for No. 2 through No. 4 main bearings. Be sure to install the thrust plates on the No. 3 main bearing cap. Remove No. 1 and No. 5 main bearing caps after No. 2 through No. 4 main bearing caps have been installed. Refer to Disassembly and Assembly, "Crankshaft Main Bearings - Remove".Install the No. 1 and No. 5 main bearing caps.
Tighten the bolts for the main bearing caps, as follows:
Tighten the bolt first on the bearing tab side of the main bearing cap to a torque of 260 14 N m (190 10 lb ft).
Tighten the bolt opposite the bearing tab side to a torque of 260 14 N m (190 10 lb ft).
Put a mark on each bolt and on each main bearing cap.
Tighten the bolt opposite the bearing tab side for an additional 120 5 degrees (2 flats).
Tighten the bolt on the bearing tab side for an additional 120 5 degrees (2 flats).
Illustration 6 g00504380
Typical example
Use Tooling (C) to check the crankshaft end play. Ensure that Tooling (C) is against a machined surface. The end play is controlled by the thrust plates of No. 4 main bearing (center).Crankshaft end play (new thrust plates) ... 0.13 to 0.55 mm (0.005 to 0.022 inch)Maximum permissible crankshaft end play (used thrust plates) ... 0.89 mm (0.035 inch)End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".